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GEA

Packaging Guide

Επίσημος Αντιπρόσωπος:Επίσημος Αντιπρόσωπος:

CFS IndustrialΛευκάδος 22, Γλυκά Νερά15354, Αττική[email protected], [email protected]τ. 210 6655240, φ. 2106655230

Contents

GEA FOOD SOLUTIONS 3

AN INTRODUCTION TO PACKAGING 4

THE FIVE FACTORS OF PACKAGING 8

GEA SOLUTIONS FOR: BAGS, VACUUM PACKS, FORMED AND PREFORMED TRAYS

GEA VERTICAL PACKAGING SOLUTIONS

HOW BAGS ARE MADE

A VARIETY OF WELDING/HEAT SEALING SYSTEMS

DIFFERENT BAG STYLES 16

DIFFERENT BAG OPTIONS 19

GEA HORIZONTAL PACKAGING SOLUTIONS 20

HOW THERMOFORMED PACKS ARE MADE 21

DIFFERENT PACKS 26

OPTIONS FOR TRAYS (IN-LINE) 34

HOW TRAYS ARE SEALED 39

DIFFERENT PREFORMED TRAY APPLICATIONS 42

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PRODUCT PRESERVATION 44

PACKAGING FILMS 45

GASES FOR MAP APPLICATIONS 46

GEA PACKAGING EQUIPMENT 47

GEA SMARTPACKER 48

GEA POWERPAK 52

GEA TWINSTAR 56

TECHNICAL DATA POWERPAK RANGE 58

A-TO-Z OF PACKAGING TERMINOLOGY 60

CUTTING FEATURES

All rights reserved ©No part of this document may be reproduced or transmitted in any form or by any means,

without prior written permission of GEA Food Solutions.

ImprintGEA Food Solutions Beekakker 11 5761 EN Bakel The Netherlands

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Content

OUR COMPANY 3



GEA SOLUTIONS FOR BAGS, TRAYS AND VACUUM PACKS 10

GEA VERTICAL PACKAGING SOLUTIONS 11

HOW BAGS ARE MADE 12

A VARIETY OF WELDING/HEAT SEALING SYSTEMS 15





DIFFERENT PACKS 26

OPTIONS FOR TRAYS (in-line) 34


PACKAGING FILMS 39



GEA SMARTPACKER 42

GEA POWERPAK 46


ADDITIONAL EQUIPMENT 48

GEA0515614881_B07.00.04EN_102015 GEA Packaging Guide Cover.indd 2-59 20/10/15 11:34

OUR COMPANY

GEA is one of the largest suppliers of process technology for the food industry and for awide range of other industries. As an international technology group, the company focuseson world-leading process technology and components for sophisticated productionprocesses. GEA takes you forward with performance-focused solutions, from singlemachines to complete production lines for the preparation, marination, processing, slicingand packaging of primarily meat, poultry, fish, seafood, confectionery, lettuce, fresh andfrozen vegetables and cheese-based products. Our equipment helps you meet today’soperational challenges such as product variety, process flexibility, uptime, reducing the costper kilogram and per pack, food safety and the environment.

GEA has a particularly long and rich history in packaging equipment. This heritage starts in 1936,when Krämer+Grebe was founded in Germany and rapidly became a pioneer in the meat processingindustry. By the sixties, the company’s Tiromat branded thermoformers were earning a strongreputation in the rapidly developing market for pre-packaged foods. These machines laid thefoundations for today’s GEA PowerPak range of horizontal form-, fill- and seal thermoformers forpackaging sliced, processed, fresh and portioned food products.

Meanwhile in the Netherlands in the fifties, Aquarius was making a name for itself with machines forthe lollipop industry and soon added vertical form-, fill- and seal machines to the range. Thesemachines have evolved into the GEA SmartPacker family of baggers. Today, these ultra-reliablemachines are used for packaging meat, fish, seafood, vegetables, potatoes, fruit, snacks, salad,cheese, confectionery and more. GEA can also supply complete line solutions for packaging a hugevariety of products.

Packing equipmentToday’s packaging product range includes:

• Horizontal form-, fill- and seal machines(thermoformers)

• Vertical form-fill- and seal machines (baggers)

• Labeling and printing solutions

• Loading and handling equipment

In addition, GEA has become an authority onpackaging types, bag formats and reclosability

From preparation to packagingIn addition to the packaging equipment, GEAalso supplies:

• Preparation equipment (mixers, grinders,bowl cutters, emulsifiers, fat analyzers)

• Marination equipment (injectors, tumblers,massagers, tenderizers, defrosters)

• Processing equipment (formers, coaters,fryers, cookers, grills)

• Slicing equipment (slicers, loaders)

• Packaging

• Lollipop production & Sugarcube lines

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AN INTRODUCTION TO PACKAGING

The twentieth century witnessed a major shift in eating habits as processed and packagedfoods gained popularity alongside fresh products. Mankind has been processing food toextend its shelf life for centuries (examples include salted and dried meats), but as newtechniques were developed to manufacture ready-to-eat and ready-to-cook foods, agrowing need emerged for individual product packaging. In the same period, supermarketsstarted to appear where customers selected products from shelves instead of beingpersonally served. These trends were driving forces for automated food packagingtechnology, an industry that kicked off in the fifties.

A brief history of food packagingEarly man consumed food where it was found, so there was little need to contain or transport it.However, with the development of agriculture and communities living in permanent settlementsinstead of nomadically chasing food sources, the first ‘food packaging’ emerged. The early forms ofpackaging were made from natural materials like grass and reed woven into baskets, and it took until8,000 years ago before ceramic containers first appeared in the Middle East. Tomb evidences showsthe Egyptians used wooden boxes, crates and barrels for bulk food packaging 5,000 years ago, andthe invention of the pottery wheel some 1500 years later heralded the emergence of mass-producedpottery. Around 300 BC, the Phoenicians and Syrians were blowing round glass containers, andaround the same time, a paper-like material made from cellulose fibers was used in China as ‘flexible’food packaging.

Traditionally packed food4

Modern packaging developmentsThe last 1,000 years has seen many changes and advances in packaging as a result of social changeand technological progress. The expansion of international trade played a part, but the mostsignificant developments in modern packaging technology have taken place since 1800.

Milestones in modern food packaging• Glass jars - 300BC

• Paper bags - 1400

• Metal cans – 1800

• Styrene foam – 1930 –1950

• Aluminium foil containers – 1950

• Aluminium can – 1957

• Cellulose packaging – 1950

• Heat shrinkable plastic films – 1958

• PET (polyethylene terephthalate) containers – 1977

Glass jarsAlthough glass-making was first industrialized inEgypt in 1500 BC and the Phoenicians madebottlelike glass containers 1200 years later, ittook until the 17th century AD when the splitmold was invented before irregular shapes couldbe easily produced. As production techniquesfurther improve in the next two centuries, theprice of glass containers gradually decreased.After the invention of an automatic rotary bottle-making machine in 1889, glass containers finallybecame economically viable for consumerproducts.

Paper bagsThe use of flexible packaging materials began with the Chinese, who also developed the techniquesfor paper making. This knowledge gradually moved west into Europe around the 14th century AD.Commercial paper bags were first manufactured in 1844 in Bristol, England, and eight years later,Francis Wolle invented a bag-making machine in the United States. The technology evolved to includeglued paper sacks, the gusset design (still used today) and in-line printed bags.

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Metal cansCanning preserves food by sealing it in an airtightcontainer. As in many technological innovations,the military played a role in the development ofcanning. During the Napoleonic Wars, theFrench government offered a 12,000 Francreward to devise a cheap and effective way topreserve food as armies on the march requireregular supplies. So in 1809, French chef andconfectioner Nicolas Appert observed that foodcooked inside a jar did not spoil unless the sealsleaked. He won the prize, and a year later theconcept was improved as glass jars werereplaced with cylindrical tin or wrought-ironcanisters (hence ‘cans’). By the mid-19th century,canned food had become a status symbol forwealthier households. Today, tin-coated steel isthe material most commonly used for cans,although the use of aluminum began in 1957and now dominates for beverage cans.

Paper cartonsAnother important use of paper in packaging was the development of paperboard as used for cerealboxes. The first ‘cardboard’ box was produced in England in 1817, although the USA-based Kelloggcompany was first to use cereal cartons. The original packaging had a waxed, heat-sealed bagwrapped around the outside of a plain box, whereas today, a plastic liner protects cereals inside theprinted carton. Another form of cardboard based on corrugated paper appeared in the 1850s.Comprising thin sheets of paperboard formed into a wavy shape and then sandwiched between twoflat sheets of paperboard, it is typically used for bulk packaging. Paper and paperboard packagingincreased in popularity throughout the 20th century. Then with the advent of plastics in packaging(late 1970s and early 1980s), paper was replaced for many applications.

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PlasticsPlastic is far newer than metal, glass, and paper. Although discovered in the 19th century, plasticswere initially used for military purpose. A wide variety of plastics have been developed over the past180 years, including Styrene in 1831, Vinyl Chloride in 1835, and Celluloid in the late 1860s.However, none of these materials were used for packaging until the twentieth century. Early Styreneproducts, for example, were brittle and shattered easily, but by the 1950s Polystyrene foam wasavailable for boxes, cups and meat trays for the food industry.

Celluloid was invented by the Hyatt brothers and first used as an ivory substitute. It could not bemolded, but was carved and shaped. Cellulose acetate was initially developed for photographic usesin 1909, and although DuPont introduced Cellophane in 1924, it wasn't commercially used forpackaging until the late 1950s.

Vinyl Chloride was first used for molded squeeze bottles in 1947 and ten years later, heat shrinkablefilms were developed from blending styrene with synthetic rubber.

One of the most commonly used packaging plastics is Polyethylene Terephthalate (PET or PETE). Thismaterial became available for beverage containers in 1977. A few years later, foods and other hot-fillproducts such as jams were also packaged in it. Today, non-oriented PET sheet is thermoformed tomake packaging trays and blisters. If crystallizable PET is used, the trays can be used for frozen oven-ready meals, since they withstand both freezing and oven baking temperatures. Other plastics usedfor packaging include High Density Polyethylene (HDPE) for personal care products, Low DensityPolyethylene (LDPE) for plastic food wrap and frozen food bags, and Polypropylene (PP) for foodstorage containers.

Overview of plastic resins (polymers) commonly used for packaging:

1. Polyethylene Terephthalate, PET

2. High Density Polyethylene, HDPE

3. Low Density Polyethylene, LDPE

4. Polypropylene, PP

5. Polystyrene, PS

6. Polyamide, PA

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THE FIVE FACTORS OF PACKAGING

Food is packaged to:

• CONTAIN – portion control, hold small items together, for example in a can, jar, bottle, bag,vacuum formed tray, pre-formed tray, etc.

• PROTECT – prevent spoilage, leakage, breakage, dehydration, contamination, theft andtampering. Physical protection – against shock, vibration, compression, temperature, etc. Barrierprotection – a barrier against oxygen, water vapor, dust, bacteria, etc.

• INFORM – identify product, explain how it should be used or prepared, warn about hazards ofmisuse, list ingredients, provide nutritional data and pricing, etc.

• PROMOTE – a marketing tool to help differentiate from similar products and attract attention inretail and supermarket outlets, for example by using brands, colors, illustrations and shapes.

• TRANSPORT – make it easier and safer to move products from the manufacturer to the warehouseand retailer (tertiary packaging) and consumer (primary packaging).

Promotion on packaging is more effective than advertisingAs the retail food business has almost completely moved from small grocers, butcher’s and otherspecialized shops to self-service supermarkets, the need to inform and sell a product via the packaginghas grown enormously. With around 10,000 products available in a typical supermarket, it is difficultto stand out from the crowd. Research shows that investments in packaging often bring higherreturns than traditional advertising!

What drives the processed food industry?The processed food industry and food package and designs follows social and economic trends in theworld.

Trends in processed foods:

• Health (nutrition, low fat, sugar free, etc.)

• Novelty (foreign and trendy products)

• Lifestyle (complete meals, ready-to-heat)

• Socio-economic (recession, population growth)

• Reconstitution (fry, oven, microwave)

• Cost efficiency

Trends influencing packaging design:

• Convenience (resealable, easy to open, portion size)

• Economy (bulk sizes, various qualities)

• Marketing (visibility, identity)

• Labeling (contents, directions, legislation)

• Sustainability (reduced, reusable, recyclable)

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Packing categoriesPackaging is typically described in relation to the type of product being packaged, for example retailfood, catering food, medical devices, pharmaceuticals, etc. It can also be categorized by layer/function, or by its rigidity.

Primary, secondary and tertiary packagingIt is convenient to categorize packages by layer or function:

• PRIMARY PACKAGING – the material that first envelops the product and is in direct contact withthe contents. This is the main application area for GEA packaging machines.

• SECONDARY PACKAGING – is outside the primary packaging, often used to group primarypackages together. Cardboard sleeves and film wrappers around the primary packaging areexamples of secondary packaging.

• TERTIARY PACKAGING – is used for bulk handling, warehouse storage and transport shipping.The most common form is a palletized unit that packs into containers.

These broad categories are arbitrary. For example, depending on the use, a shrink wrap can beprimary packaging when applied directly to the product, secondary packaging when bundling smallerpackages, and tertiary packaging on some palletized distribution packs!

GEA PowerPak thermoforming, GEA TwinStar traysealing machines and GEA SmartPacker verticalpackaging machines are mainly used for primary packaging (packaging material is in contact with thecontents) and secondary packaging.

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GEA SOLUTIONS FOR BAGS, TRAYS AND VACUUM PACKS

GEA has the know how and expertise to give you a headstart by providing

a total package for fresh and frozen food, confectionery, non-food and

medical packaging. Over the years we have installed many complete lines

in all corners of the world, and all have been developed hand-in-hand

with the customer. Naturally, our total solution approach extends to

complete systems with all peripheral equipment such as transport,

labeling and printing. We help you keep products fresher for longer, take

care of lowest cost per pack and provide visually appealing packages to

win attention in supermarkets and other outlets.

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A variety of bags, with a wide range of options can be made on our

equipment. Depending on your needs you can select the type that suits

your product and customer best. On the next pages we will explain how

these bags are made.

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HOW BAGS ARE MADE

Working principleThe typical machine is loaded with a flat roll of plastic film, which has artwork applied to the exterior orinterior of the film.

The film approaches the back of a long cylindrical tube, which is called the forming tube. When thecenter of the plastic is near the tube, the outer edges of the film form flaps that wrap around theconical forming tube. The film is pulled downward around the outside of the tube and a vertical heat-sealing bar clamps onto the edges of the film, bonding the film by melting the seam edges together.

To start the bagging process, a horizontal sealing bar clamps across the bottom edge of the tube,bonding the film together, and cutting off any film below. This sealing bar can be at a fixed height,which is called an intermittent sealing process. Faster systems include a sealing bar that moves downwith the bag while sealing. This is called a continuous process. When the gross weight of the product-filled bag is reached, filling stops, and the horizontal sealing bar seals the top of the bag,simultaneously forming the bottom of the next bag above. This bag is then cut off from the tube and isnow a sealed package, ready to advance onward into the product boxing and shipping processes.

The feeding of material and cutting of the bag can be determined either by bag length, or by indexingto an eyespot, which is detected by a visual sensor.

Many food filled packages are filled with nitrogen to extend shelf life. Food manufacturers are oftenlooking for ways to improve their geographical reach or otherwise extend the shelf life of theirproduct without the use of chemicals. Nitrogen filling is a natural means of extending shelf life.

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Process stepsStep 1: Product enters through the forming tube

Step 2: Rollers guide film to forming shoulder

Step 3: Forming shoulder shapes flat film into round tube

Step 4: Longitudinal edges of the film are sealed, bonding the film together

Step 5: Tube is cross sealed so bottom/top is made

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GEA SmartPacker SX, intermittent motionThe product falls onto the closed jaws. The jawsopen and the vacuum belts transport the filmthrough the open jaws. When the right baglength is reached, the jaws close and film issealed and cut. The cycle continues as the jawsopen again to release the sealed bag.

Technical details:

• bag widths of min 70 max 400 mm.

• bag length max 550 mm.

• max speed is up to 100 bags per minute

GEA SmartPacker CX, continuous motionThe product falls onto the closed jaws. As thebag fills, the downward movement of the jaws issynchronized with the film transport and the filmis sealed and cut. The jaws open to release thesealed bag and return to the top to form the nextbag.

GEA SmartPacker TwinTubeThis uses the same technology as the CX, butexecuted with a double set of tubes next to eachother, so twice the speed. It is ideal for calorieand similar bag formats.

Technical details:

• bag widths of min 70 max 400 mm.

• bag length max 550 mm.

• max speed is up to 250 bags per minute

GEA SmartPacker CX 400

GEA SmartPacker CX250


GEA can offer a comprehensive choice of sealing options to suit a wide

variety of packaging film types.

GEA Heat seal technologyThis system heats the jaws continuously foroptimal temperature control, so allowing for theback and front jaws to be adjustedindependently. Jaws are available with differentserration types and optional euro, longitudonalor punch hole.

GEA Ultrasonic seal technologyUltrasonic sealing of bags uses high-frequency‘ultrasonic’ vibrations of the sonotrode to bondthe two layers of film together at a molecularlevel. Even if moisture or small particles of debrisremain in the sealing area, an airthight seal is stillpossible. GEA has a patent pending technologyto seal film 30- micron OPP film that deliversconsistent results.

GEA Induction seal technologyInduction sealing uses an indirect way to heat thesealing wires. This system requires no heating-uptime and maintains a constant temperature overthe full length of the sealing wires. This superior,patent pending, induction technology simplifiesthe sealing concept and therefore reducesdowntime.

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DIFFERENT BAG STYLES

The GEA SmartPacker offers an extensive choice of bag formats directly from the reel. Withthese different formats, from standard flat pillow bags to more complex quatroseal orzipper bags, GEA offers a packaging solution that is right for each product.

Pillow

Characteristics

• Most common bag style

• Simple to produce

• High speeds possible

Gusset

Characteristics

• Pillow bag with side gussets

• Gusset is considered to be the depth ofthe bag

• Suitable for “bag-in-box” solution

Blockbottom

Characteristics

• Side gusseted bag

• Cost-effective stand-up format

• Good appearance on the shelf

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Quatroseal

Characteristics

• Flat bottom

• Stand-up pouch with 4 corner seals

• Attractive on the shelf

• Maximum promotional effect

Doystyle

Characteristics

• Excellent facing

• Popular bag style

• Large printing surface

• Replaces pre-made bags

Envelope

Characteristics

• Bag with re-sealable flap

• Double-sided adhesive tape

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The choice of bag style depends on:• Customer perception/market segment – for example, is it a high-end luxury product or budget

supermarket product? Some formats have a high-quality appearance, while others are better forapplications where price is the main driver.

• Product characteristics – whether the products are fresh, frozen, grated, moist, wet, fragile andso on also influences the choice of bag format, sealing technique and material.

• Volume/weight combination – some bag formats are able to hold larger volumes or supportmore weight than others.

• Shop presentation – formats with a flat base can be used for stand-up presentation on shelvesand in upright freezers whereas other are intended for lying in a chest-type cooling- or freezercabinet. All formats are suitable for hanging presentation (Euro punch or longitudinal hole).

• Modified Atmosphere Packaging (MAP) – the requirement to inject a gas (such as O2, N2 or CO2

to increase shelf life) into a bag influences the choice of bag format, sealing technique and material.

• Convenience – additional features are available on most formats to make the bag moreconvenient for consumers, such as reclosable zipper, reclosable tape, and easy-tear opening.

BAG SELECTOR Protein Frozen (vegetables/French fries) Fresh (salad/cheese) Confectionery

Pillow I I I I

Gusset I

Blockbottom I I I I

Envelope I I cheese only I

Quatro I I I I

Doystyle I I I cheese only I

I available as standard

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DIFFERENT BAG OPTIONS

Reclosable zipper

Perforation

Label

Print

Europunch

Easy-tear

Reclosable tape

Modified Atmospere Packaging

GEA HORIZONTAL PACKAGING SOLUTIONS

GEA Vacuum packsThese give excellent product presentation withlong shelf life and low material use. Openingfeatures such as Peel corners, tear off cutting andeven reclosable packs with Zipper application areavailable.

GEA TraysA formed tray is an excellent solution topack products in a transparent pack (MAP) or askinpack. Any MAP application can be combinedwith peel easy opening features or even re-closable function.

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HOW THERMOFORMED PACKS ARE MADE

Working principle• Bottom film is fed into the transport chains.

• Film is heated in the pre-heater or forming lid heater.

• Film is formed into the forming mold by use of vacuum and / or compressed air and / or Optiformplug-assist.

• Trays are getting filled with product.

• Top film is supplied into the sealing station.

• Tray with product gets evacuated through narrow top film, side holes or cross nozzle bar, optionallymodified atmosphere is applied and the pack is sealed.

• Optionally packs are labeled in the labeling station.

• Packs are cut, either by cross cut guillotine for flexible film or by cross cut punch for rigid film.

• Longitudinal cut is executed by rotating knives or squeeze knives for rigid as well as flexible film orroller shear cut system.

• Packs are leaving the machine on the out feed conveyor, while side waste gets removed.

The result is a high quality pack which meets the GEA standard expected by all GEA PowerPakthermoformers.

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Infeed section Forming stations Filling section Sealing station

GEA AIR/BLISTER packIndex film

> Heat film > Form film Fill product > Seal films

GEA VACUUM packIndex film > Heat film > Form film Fill product > Vacuumize > Seal films > Ventilate

GEA SKIN packIndex film Heat film > Form film Fill product Delayed vacuumize product > Heat

topfilm > Seal films > Ventilate topprior to bottom

GEA MAP packIndex film > Heat film > Form film Fill product > Vacuumize > Refill gas > Seal films

> Ventilate

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HOW PACKS ARE MADE

Working principle

Labeling station Cutting station Lane converger After treatment End

Production / Expiring DateTraceability

Cut pack Re-format Sell







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Infeed section Forming stations Filling section Sealing station

GEA SHRINK packIndex film > Heat film > Form film Fill product > Vacuumize > Optionally MAP >

Seal films > Ventilate

GEA STEAM EVACUATION packIndex film Heat film > Form film Fill product > Inject/flush steam > Seal films

GEA COOK-IN-PACKIndex film Heat film > Form film Fill product > Inject/flush steam > Seal films

ALTERNATIVELY:> Vacuumize > Seal films > Ventilate

GEA TiroBoxIndex film Heat film > Insert cardboard

tray > Form into tray > Sealfilm to tray

Fill product > Vacuumize > Refill gas > Seal films> Ventilate

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HOW PACKS ARE MADE

Working principle

Labeling station Cutting station Lane converger After treatment End


Cut pack Re-format Shockheat pack Sell




Cut pack Re-format Cook pack Sell


Cut pack Re-format Cook pack Sell



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GEA Air/Blister pack

An Air/Blister pack is a pack which contains a product and is sealed only.

There is the option to evacuate the pack slightly.

Arguments for using GEA Air/Blister pack application

• Protection

• Hygiene (sterilization)

• Easy handling

• Theft prevention for smaller items

Applications for GEA Air/Blister pack:

• Medical disposables

• Non-food products

• Frozen food products

Medical disposables Consumer products Poultry

Infusion bags Toothbrushes Ready meals

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GEA Vacuum pack

A Vacuum pack is an airtight pack. All the air is removed from the pack

before sealing. When ventilated the film covers the product completely.

Arguments for using GEA Vacuum pack application

• Long shelf life

• Economical packaging with clear product presentation

Applications for GEA Vacuum pack:

• Meat (ham, sausage, poultry, marinated ribs, sate)

• Cheese (blocks, sticks, slices)

• Seafood (fish fillets, smoked, marinated fish)

• Frozen food (pastry, dough)

• Ready meals (potato, vegetables)

Salami Vegetable aspic Pre-cooked potatoes

Cheese Sausages Surimi

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GEA Skin pack

A Skin pack in principle is a vacuum pack. The heated top film is put over

the product, this process effectively covers the product with a "second"

skin and generates a fusion seal around the product.

Arguments for using GEA Skin pack application

• Excellent shelf life

• Attractive presentation

Applications for GEA Skin pack:

• High quality sliced products (meat, cheese, fish)

• Meat cuts / sausages (fresh / cooked / roasted)

• Fish cuts (fresh / cooked / roasted)

• Hard cheese

• High-end products (e.g. top quality seafood, scallops)

The product gets a very nice presentation as if it is just lying on a plate or in a tray.

Beef Seafood Turkey

Spanish pork Salmon Duck

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GEA MAP pack

A MAP pack is a Modified Atmosphere Pack, in which the air is first

pulled out of the pack. After this vacuuming process a pre-defined gas-

mix is added and the pack is sealed.

Arguments for using GEA MAP pack application

• Fresh image of product presentation

• Extension of shelf life

• Convenient handling of final product

Applications for GEA MAP pack:

• Meat / sausages / minced meat

• Fish cuts

• Cheese / sliced products

• Ready meals / pasta

• Vegetables / fruits / nuts

• Bread / pastry

Cheese Hotdogs Pizza

Salami Case ready Pastry

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GEA Shrink pack

A Shrink pack in principle is a vacuum pack. It is made from special

shrinkable top and bottom film. The shrinking effect is obtained by

passing the packaged product through a hot air tunnel / waterbed.

Arguments for using GEA Shrink pack application

• Long shelf life

• Attractive wrinkle free

• Allows different product sizes to be packed in one pack size

Applications for GEA Shrink pack:

• Fresh meat / meat parts / marinated meat / sausages

• Whole chicken / chicken parts

• Cheese blocks (to ripen or ready to eat)

• Lamb legs

• Cooked hams

Poultry Bacon Cheese block

Sausages Meat cuts Cheese

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GEA Steam Evacuation pack

Steam Evacuation pack is a vacuum pack where the fresh cooked, roasted

or heat-treated product is filled hot. The product can be solid and/or with

sauce. When filled, the hot product (preferably at around 85°C) gets

steamflushed in the sealing station. The result is a full vacuum pack with

optimal shelf life.

Arguments for using GEA Steam Evacuation pack application

• Long shelf life

• Hot product with or without sauce

• Cost saving (no cooling process before packaging)

Applications for GEA Steam Evacuation pack:

• Ready meals with sauce

• Pasta

• Vegetable dishes

• Soups

• Roasted / cooked meat / chicken / chicken parts

• Cooked fish

Pasta Meatballs Turkey

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GEA Cook-in-pack

A Cook-in-pack is a pack which is filled with a raw material and after being

sealed, the product is cooked inside the pack. This is a typical application

for the manufacturing of cooked ham.

Arguments for using GEA Cook-in-pack application

• Cost saving

• Enhanced product quality output

• Raw material may vary in size

• Much longer shelf life

• Prevents yield loss

Applications for GEA Cook-in-pack:

• Cooked ham

• Paté

• Fish paté

Cooked ham D-shaped ham Paté

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GEA TiroBox

TiroBox is a ready-folded cardboard packaging that is lined with a film

directly in the packaging machine, then filled and sealed. The pack can be

heated in the microwave and is ideally suited for packaging convenience

foods or snacks. Consisting of as much as 70 % renewable resources, this

kind of packaging meets the trend to use more renewable materials.

Arguments for using GEA TiroBox application

• Ecologically sustainable: after use the cardboard and film are separated for waste disposal

• Machine can be used for the production of TiroBox and also for standard packages

Applications for GEA TiroBox:

• Ready meals

• Noodle snacks

• Rice snacks

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OPTIONS FOR TRAYS (in-line)

Easy opening features

Peel corner for easy opening

Opening slot

Chevron peel

Peel corner for easy opening

Zig-Zag opening

Peel flap

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Reclosability

FlipFresh with sloped forming

Press-to-Close zipper

Click-to-Close reclosability

FlipFresh Classic

Slider zipper

Adhesive film

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OPTIONS FOR TRAYS (in-line)

Special cutting features

Special contour cut

Complete contour cut

Euro hole

Contour cut

Complete contour cut

Round hole

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Labelling and printing options

Top web label

Bottom web label

Printing on top film

Top web label

Bottom web label

Printing on label

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PRODUCT PRESERVATION

One of the main reasons for packing food products is to protect the

product against deterioration and to achieve a time-frame in which the

product can get distributed to the retailers while still keeping its freshness

as much as possible. It is definitely needed that all the steps and

treatments the product has to go through are carefully executed. This

routing starts already where the product is cropped / processed and

transported to the factory and it ends when the consumer opens the pack.

A spoiled product cannot be improved by a pack; it only becomes worse

by the time and mistreatment. The influence the pack has on the quality of

the product is the possibility to extend its natural shelf life. This extention

of natural shelf life can be achieved by evacuating all the environmental

air from the pack by creating a vacuum pack, or by using MAP. This MAP

packaging should be done in combination with the right films to keep the

gases as long as possible inside and the air / microbes outside the pack.

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PACKAGING FILMS

Mono-layerFilm made out of one single layer, the base material to make these films can vary, depending on usageand further processing.

Multi-layerThis type of film is made out of structured layers of different materials, the order in which these areused as well as the material can vary depending upon the technical needs and usage.

Film typesTo pack a product, there is a very wide range of films available. For vertical packaging mono- andmulti-layer films are used, for horizontal packaging multi-layer are applied and split up in two groups,flexible and rigid.

Base materials for most common packaging film-compositions:

• PA Polyamid (body layer)

• PET Polyethylenteraphthalat (Polyester) (body layer)

• PP Polypropylene (body layer and / or sealing layer)

• PE Polyethylene (sealing layer)

• EVOH Ethylen-Vinyl-Alkohol-Copolymer (barrier layer)

• I Ionomer /Surlyn (special sealing layer)

• PS Polystyrene (body layer)

These base materials are used in endless combinations (multi-layer) to suit relevant applications andneeds for your product like protection, presentation, information, etc. In the end there are always twoitems which will decide which film will get applied:

• Is the material the best choice for the product and pack-application?

• Is it the most economical way to fulfill the needs of the pack?

To get the right answer to these questions, a discussion with the film supplier and GEA will be needed.

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GASES FOR MAP APPLICATIONS

Mainly three gases are used for MAP packaging:

• Carbon dioxide CO2

• Nitrogen N2

• Oxygen O2

MAP gases are generally used in a mix, from which the composition is strongly dependent on theproduct to pack. The most commonly used gas mix is a mix of CO2 and N2 in a ratio 30% to 70%.

Typical property of the common MAP gasesCarbon dioxide is an active gas. In percentages of 20% or higher in a gas-mix where no O2 is present,

the product will react to this gas: it will slow down the growth of bacteria and mold. At the same timethe CO2 gets absorbed by the fat and water inside the product. A side effect of this process can be that

the product gets a slightly acidic taste. Nitrogen is an inert gas, which means that there is no reaction at all from the product on the presenceof this gas inside the pack. It is only used as a filler gas; to fill the pack to a neutral shape after the air iscompletely evacuated and the pack is refilled with gas. The refilling takes place with the for theproduct required amount of the active gases CO2 and / or O2 and N2. For some products 100% N2 is

also used as a MAP gas.

Oxygen is a gas which is needed to keep biological life intact. For this reason it is principally notwanted as a gas to extend shelf life of the product, because all the microbes which will deteriorate thefood are kept alive too.

For some foods however, a high ratio of O2 is used to keep the color intact: red beef meat is commonly

MAP packed in a gas mix ratio of 80% O2 and 20% CO2. A higher ratio of O2 than the normally

ocurring 21% in air (~50%) will turn the microbes overactive and kill them in a short time.

Tips:

• To avoid getting a vacuum pack with a product that strongly absorbs CO2, the ratio of

CO2 in the gas mix should not be too high. If there is no filler gas present, it is possible

that the pack at the end gets a vacuum pack.

• When using O2 in a higher concentration than outside air (> 21%), a special gas system is

needed.

• A considerable expertise on gas, gas mixes and its influence on food products is availableat the gas suppliers.

40

GEA PACKAGING EQUIPMENT

Packaging plays a critical role in attracting attention, and will help

convince consumers to choose your products. So at GEA, we help you

create package configurations and designs that contribute to sales

success. Close contact with our customers for packaging solutions in

combination with our extensive experience in equipment for food

preparation, marination, processing and slicing give us a unique

understanding of the challenges you face. Our innovative machines are

also excellent for packaging medical and technical products in well-

designed, safe and hygienic packages.

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• Compact, high speed and flexible machine, easy to use

• Creates a wide variety of bag shapes (pillow bags, gusset, block bottom, quatro seal, envelope,doystyle and zipper bags)

• 400 mm maximum bag widths for pillow bags

• Hygienic design with easily exchangeable parts

• Option to combine a ZipTrick system to the machine for recloseable packs

Due to its continuous film transport system, theGEA SmartPacker CX can operate at higherspeed than intermittent machines. The GEASmartPacker offers an excellent price/performance ratio. Reliable and user-friendly,the machine is easy to operate and clean, whileits advanced technical design keepsmaintenance costs to a minimum. The GEAvertical packaging machine offers a convenientand inexpensive means of packaging a widevariety of convenience goods, mainly protein,fresh salad, shredded cheese, frozen vegetables,French fries, confectionery and snacks.

In addition, the GEA SmartPacker has anextremely sensitive 'product in seal’ detectionsystem, which automatically opens the jaws assoon as an object or product particle is detected– without disrupting production. A majoradvantage is that contamination or damage ofthe cross seal jaws and knife is avoided resultingin less downtime and waste.

Your performance benefits

• Higher efficiency and less wastecompared with conventional machines

• Consistent high quality of packagesproduced at up to 120 bags per minute

• Reliable and smooth film transport

• Quick film reel and bag format exchange

• Compact and easy accessible film feed

• Easy to operate, clean and maintain

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GEA SmartPacker SX400

• Compact and flexible machine, easy to use

• Creates a wide variety of bag shapes (pillow bags, gusset, block bottom, quatro seal, envelope,doystyle and zipper bags)

• 400 mm maximum bag width for pillow bags

• Maximum bag length 550 mm

• Hygienic design with easily exchangeable parts

• Option to combine a ZipTrick or in-line zip system to the machine for re-closeable packs

Based on an intermittent machine action, theGEA SmartPacker SX has an excellent price/performance ratio. Reliable and user-friendly,the machine is easy to operate and clean, whileits advanced technical design keepsmaintenance costs to a minimum. The GEAvertical packaging machines offer a convenientand inexpensive means of packaging a widevariety of convenience goods, mainly protein,fresh salad, shredded cheese, frozen vegetables,French fries, confectionery and snacks.



• Higher efficiency and less wastecompared with conventional machines

• Consistent high quality of producedpackages up to 100 bags a minute

• Reliable and smooth film transport


• Compact and easy accessible film feed

• Easy to operate, clean and maintain

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• Super-fast – fills up to 250 bags per minute

• Bag width - 70 to 250 mm

• Large 2500 g bags can be filled

• Lower risk of damaging fragile products during filling

The GEA SmartPacker CX250 configuration canpackage up to 250 bags per minute – and canhandle large format 2500 gram bags. Themachine is designed with a considerably lowdrop from the top funnel to the center jaw,which not only increases capacity and speeds upthroughput, but also has benefits for fragileproducts like hard candy, chocolate, biscuits andcookies.



• Hygienic design with easily exchangeableparts

• Reliable operation with smooth filmtransport

• Higher efficiency and low filmwaste

• Easy access to film track from all sides


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GEA SmartPacker TwinTube C

• High output up to 500 bags per minute

• Bag width - 50 to 145 mm

• Significantly lower investment than for four high-speed baggers

• Accelerated Return-on-Investment

• Space and cost savings through efficient use of factory space (limited machine height)

• Less operating costs, lower cost per bag

• Flexible packaging (optional to run single reels per tube)

With a bag production output up to 500 bagsper minute - up to four times the speed ofconventional lines - the GEA SmartPackerTwinTube C high-speed bagging system bringsyou productivity benefits. The GEA SmartPackerTwinTube C synchronizes two forming tubes ona single machine but offers even more flexibilitywith the option of running a single film reel foreach tube. This allows you to simultaneously runcalorie packs with different sizes andappearances.



• Just 1450 mm high, including metaldetector

• Consistent high quality of packagesproduced at up to 500 bags per minute

• Servo driven unwind shaft

• Two separate film rolls as option

• Unique film control system

• Optimal synchronization with high speedweigher

• Easy access / easy maintenance

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GEA PowerPak range

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GEA PowerPak range

The GEA PowerPak range is an innovative thermoformer concept for the

highest packaging standards, most complex applications and highest

output demands. This machine combines unsurpassed top performance

with outstanding cost-saving potential thanks to low machine

downtimes. A boost to help you achieve your personal peak performance.

• Long equipment lifetime

• High machine availability: continuous performance monitoring allows you to use the machine tothe best of its potential.

• Real-time equipment performance analysis at operator level through GEA CostFox software.

• High cost saving potential depending on application

• Changing of label rolls without stopping the machine.

FlexibilityDesign your requirements in consultation withus, and GEA will configure the optimalthermoformer for you. The best of all: thismachine is flexible so you do not need todetermine a single configuration for its entirelife. With the modular construction of the GEAPowerPak range you can build a machine whichis uncompromisingly tailored to yourapplications of today, and still remain open tothe demands of tomorrow.


• Longer service life

• Reliable quality

• Wide variety of output

• Intuitive operation

• Needs-oriented flexibility

• Useful analysis program

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Additional equipment

GEA TiroLabelThe cross web labeler is applying labels to the topor bottom film for a thermorformer application.With its spring loaded finger system the GEATiroLabel is globally unique.

GEA TiroPrintGEA offers more integrated printing solutionsthan any other manufacturer of packagingmachines. This means the optimal printer isalways available for every job and surface.

GEA PowerGuideFully automatic smart outfeed system forinterfacing with GEA thermoformers. It assistsgreatly all line control and puts packs into asingle lane with the maximum possible pitchingbetween them. GEA EasyGuide is available formedium-and low capacity.

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GEA EasyCheckCompact checkweighing system with built-inmetal detector. It recognizes products with metaldecontamination and incorrect weights. This is acomplete inspection system in compliance withthe modern requirements from HACCP, IFS, BRCand others.

GEA PowerPickIntelligent outfeed system features automatedsingle pack rejection and ensures accurate singlelining of filled packs at the outfeed of thepackaging machine. Rejected packs areconfirmed and documented for due diligencepurposes and the reject collection area isconstantly monitored. The outfeed can beconfigured for single or twin lines.

GEA FlexLoaderFor fully automated loading of sliced portionsand minced meat into thermoformers andtraysealers. It provides outstanding flexibility andis quickly changed over to accommodate variousformats for the packaging machine.

GEA RobotLoaderThe GEA RobotLoader offers outstandingproductivity and almost unlimited options forproduct positioning. To enable customers tomeet these requirements as effectively aspossible, GEA has developed a fully integrateddelta robot system.

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A-TO-Z OF PACKAGING TERMINOLOGY

A - C

Aseptic packaging – a technique for creating a shelf-stable container by placing a commerciallysterile product into a commercially sterile container in a commercially sterile environment. The sealedcontainer maintains product sterility until the seal is broken.

Back seam – a bag seal that runs down the middle of the back (vertical direction). Made by form-, fill-and seal machines.Bacon wrapper paper – a greaseproof or vegetable parchment paper or a laminated product madefrom other materials that are used for wrapping bacon. Bagger, bagging machine – a vertical form-, fill- and seal machine (such as the GEA SmartPacker)that forms a bag from a roll of flat material, fills it with product and seals the ends.Barrier – the ability of a material to stop or retard the passage of atmospheric gases, water vapor, andvolatile flavor and aroma ingredients. A barrier material is designed to prevent the penetration ofwater, oils, water vapor, or certain gases. Barrier materials may exclude or retain such elements insideor outside a package.Base film – or bottom film.Blister pack – a package type where the item is secured between a pre-formed dome or ‘bubble’ anda paperboard or flexible carrier. It is also referred to as a bubble pack. The pack may be evacuatedslightly. It is often used in medical packaging and other non-food applications.Blockbottom – a side-gusseted, stand-up bag format.Bottom film (infeed) – the film roll that forms the bottom part of the pack at the forming station.See also top film.Bottom/top (or horizontal) seal – the bond between two layers of film made by a heated bar(element) which may also separate the bag from the roll. Bottom sealed bags are separated by a knife.Breathing package – packaging material that allows air to enter or leave under varying conditions,including temperature changes. Most wrap used for fresh red meat allows enough air to pass throughto keep the proper color in the meat.

Carbon dioxide (CO2) – an active gas that slows down growth of bacteria and mold in MAPapplications.Continuous motion packaging – a vertical form-, fill- and seal process in which the horizontal sealsare made on the bag as it travels through the machine. This enables it to operate at a greater speedthan intermittent motion machines. The GEA SmartPacker CX baggers are continuous motionmachines.Contour cut – a tray specially formed and trimmed to follow the shape of a specific product.Controlled Atmosphere Packaging (CAP) – a packaging method in which concentrations of gasesare maintained throughout storage in order to extend the product’s shelf life. Gas may either beevacuated or introduced to achieve the desired atmosphere. See also Modified AtmospherePackaging.Cook-in-pack – a unique GEA pack format for products that are packaged raw and then cookedinside the pack, for example, cooked ham and paté.Cross nozzle bar – a unique GEA vacuumizing and MAP system for the PowerPak's: over cross thefilm direction between top- and bottom- film, which saves film costs.

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D - F

Degradation – a change or break-down in a material's chemical structure.Dehydration – loss of moisture.Delamination – separation or splitting of laminate layers caused by poor adhesion or mechanicaldisruption.Doystyle – a flat-bottomed bag format that replaces pre-made bags.

Easy-tear – a v-shaped cut-out on the edge of the seal to make it easy to tear open.Envelope – a reclosable bag format.Euro hole (or Europunch) – a standardized cut-out (combining a horizontal slot with a central largerdiameter hole) at the top of a bag or pouch that allows hanging display. See also longitudinal punch.EVOH – ethylene-vinyl alcohol is commonly used as an oxygen barrier in food packaging films.Eyemark or printmark – small, black lines on the edge of the packaging film that are repeatedthroughout the length of the roll in precisely the same spot in relation to the printed design. They aredetected by the machine and indicate when an action is required. Fin seal – a back seal created when the inside edges of the substrate are bonded, leaving the seamstanding out from the package, for example, on potato chip bags.Flexible packaging – a package, bag, envelopes, pouch, wrap or container made of flexiblematerials that can be readily changed in shape when filled and closed. Flexible packaging can besingle- or multi-layered and is typically supplied on reels. FlexLoader – a GEA solution for automated loading of portions into a thermoformer or tray sealer.Flexographic printing – a method of printing using flexible printing plates in which the image to beprinted stands out in relief. FlipFresh – a reclosable lid for trays.Foam trays – made from expanded polystyrene (EPS) and formed by adding foaming agents topolystyrene and passing it through a die. Foreign Object Detection (FOD) – a GEA patented system to boost food safety in productspackaged on a tray sealer.Form-, fill- and seal machine – machines that package products by creating packages, such as a bagor tray, fill them with product and then seal the package in one in-line process. The machines can beeither vertical (such as the GEA SmartPacker) where the product is dropped into the package beforefinal sealing, or horizontal (such as the GEA PowerPak) where the product is placed into the packagehorizontally, for example, by a robot loader.Forming station – the part of the thermoformer where the trays (bottoms of the packs) are drawninto a vacuum forming chamber. See also sealing station.Forming tube – a long cylindrical tube that guides the flat film from a roll into a tube ready to bemade into bags. Each bag format on a vertical form-, fill- and seal machine requires a dedicatedforming tube.

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G - L

Gas flush – a procedure used in food packaging where gas is used during the packing process toevacuate oxygen and moisture before the package is sealed.Good Manufacturing Practice (GMP) – implies that the entire manufacturing procedure has beendesigned in such a way as to produce a quality product that presents a minimum risk to the consumer. Gusset – a fold in the side or bottom of the pouch, allowing it to expand when contents are inserted

Heat seal technology – the conventional sealing technique that welds two layers of film togetherusing heat.Hermetic seal – a seal that is airtight or impervious to gases or fluids under normal conditions ofhandling and storage.High barrier – a material or package that has very low gas permeability characteristics, and thereforeoffers a great deal of resistance to the passage of a gas through its volume.

Induction seal technology – a technique that indirectly heats the sealing wires very evenly over thewhole length of the seal. It requires fewer wires than conventional heat sealing and is therefore moredurable.In-line process – an industrial process carried out using a line of equipment that continuouslyprocesses products without the need to stop and reload. Intermittent motion packaging – a vertical form-, fill- and seal process in which the horizontal sealsare made on the bag while the film tube is temporarily stationery in the machine. This means itoperates at a lower speed than continuous motion machines. The GEA SmartPacker SX baggers areintermittent machines.

Jumbo Unwind – an option for unwinding film reels up to 1.000 mm diameter.

Laminated (or multilayer) film – an adhered combination of two or more films or sheets made toimprove overall characteristics. Lap seal – a back seal is made when two layers of substrate overlap, forming a bond with no materialstanding out from the package.Line – a row of interconnected processing equipment to form, coat, cook, freeze, and package foodproducts.Longitudinal (or vertical) seal – the vertical seal formed by bonding the two edges of the film rolltogether to make a tube. Also known as back seam.Longitudinal punch – a standardized horizontal slot cut-out at the top of a bag or pouch that allowshanging display. See also Euro hole.LowDrop – a unique GEA SmartPacker configuration that reduces the distance products travels toreach the bag, and therefore reduces the risk of damage to fragile products during filling.

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M - P

MAP – see Modified Atmosphere Packaging. Modified Atmosphere Packaging (MAP) – a packaging method in which a combination of gasessuch as oxygen, carbon dioxide and nitrogen is introduced into the package at the time of closure.Purpose is to extend shelf life of the product packaged. See also Controlled Atmosphere packaging.

Nitrogen (N2) – an inert gas used as a filler in MAP applications.

Opening slot – an easy-opening feature for tearing open trays.OptiChange – the GEA solution for simple and safe tool changing on a thermoformer.Optiform plug – a plug system in a closed pressure box which allows forming air fill (even while theplug is going down).Ovenable board – a paperboard that can be placed in a microwave or conventional oven to serve asthe cooking utensil for food. Oxygen (O2) – although oxygen stimulates growth of all biological life, and therefore not used as agas to extend shelf life, it is sometimes used to preserve the red color of red meat.Oxygen Transfer Rate (OTR) – a material’s barrier abilities against oxygen. This is important in foodpackaging, as oxygen can decrease shelf life of a product.

PA – polyamide Packaging – the enclosure of products in a wrap, pouch, bag, box, cup, tray, can, tube, bottle orother container.PE – polyethylene Peel corner – an easy-opening feature for removing the top film of trays.Peel flap – an easy-opening feature for removing the top film of trays.Perforation – a series of small punched holes to make a package easier to open.PET – Polyethylene Terephthalate.Pillow pouch – a bag or pouch in the form of a tube that is sealed at both ends. Pillow type pouchesare most commonly produced on vertical form-, fill- and seal machines (such as the GEA SmartPacker)and are characterized by seals across the top and bottom, and a longitudinal seal down one of thefaces.Plastic – collective name for synthetic packaging materials such as styrene, vinyl chloride, PE, PET, etc.Polyethylene (PE) – a low cost soft flexible material often used as an outer wrap. PE is also used as asealant layer for laminates, due to its ability to create hermetic seals.Pouch – a small bag usually constructed by sealing one or two flat sheets along the edges. There is nodistinction between a pouch and a sachet other than the common understanding that a sachet issmaller.PowerGuide – a GEA solution for directing packs into a single lane at the outfeed of a thermoformer.PowerPak – the GEA range of thermoformers.PowerPick – a GEA solution for directing packs into a single lane at the outfeed of a thermoformer.PP – polypropylene Press-to-close zipper – a reclosable zipper format.

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P - S

Primary packaging – packaging where the material is in contact with the product being packaged.See also secondary packaging and tertiary packaging.Product-in-jaw detection – a unique GEA system that ensures the thermal sealing jaws of a GEASmartPacker do not close when an object is present in the seal area. This prevents sticky productsfouling the jaws and therefore causing unnecessary downtime. PS – polystyrene Punch hole – a standardized circular cut-out at the top of a bag or pouch that allows hanging display.See also Euro hole.PVDC – polyvinylidene chloride is used as a coating increasing the barrier properties of the filmreducing the permeability of the film to oxygen and flavors and thus extending the shelf life of thefood inside the package.

Quatroseal – a flat-bottomed, stand-up pouch with four corner seals.

Ready-to-eat – products that have been fully cooked during processing and only have to bereconstituted (re-heated) by the consumer to eat.Ready-to-heat – products that have been coated during processes (and may have had the coatingflash-fried to harden it) but have not been cooked (still raw). The consumer has to cook the productfully, not just re-heat it.Reclosable tape – a strip of double-sided adhesive tape that enables a bag to be reclosed after it hasbeen initially opened.RobotLoader – a GEA solution for automated loading of products into a thermoformer or tray sealer.Roll stock – any flexible packaging material that is in a roll form.

Seal (or bond) strength – refers to the integrity of a connection between 2 or 3 materials bondedtogether. Sealing bar – a horizontal set of jaws that clamp the tube on the vertical form-, fill- and seal machineand use heat (or ultrasonic energy) to make a horizontal seal that forms the bag. On a continuousmotion machine, the sealing bar moves down with the film as it passes through the machine, whereason an intermittent motion machine, it is at a fixed height.Sealing station – the part of the thermoformer where the trays (bottoms of the packs) are drawninto a vacuum forming chamber. See also forming station.Secondary packaging – packaging applied outside the primary packaging to group items together.See also primary packaging and tertiary packaging.Shelf life – used for food products to indicate the effective life of a product from the date ofpackaging to when it is no longer suitable for consumption. Products beyond their effective date mustbe removed from inventory shelves because they are likely to be stale.Shrink pack – a vacuumized pack format that uses film that shrinks to tightly fit the product,delivering an attractive and wrinkle-free result.Side holes – holes in the bottom film at the chain-sides, to make product vacuumizing and MAPpossible.

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S - V

Skin pack – an attractive vacuumized GEA pack format that follows the natural shape of the productbeing packaged like a second skin. Slider zipper – a reclosable zipper format.Sonotrode – the ultrasonic jaws that vibrate at a very high frequency to bond two layers of filmtogether. Stand-up pouch – a flexible pouch design where the bottom portion is gusseted so that it provides awide base to enable the package to be stood up for display or use. The flat-bottomed Doystyle is anexample.Steam evacuation pack – a GEA pack format for freshly cooked, roasted or heat-treated productsthat are packed while still hot. Surface print – a process where ink is deposited directly on the outer surface of the packaging filmthat is commonly used for short run printing. A UV coating may be added to provide a hard finish thatstops the ink flaking or chipping.

Tertiary packaging – packaging used for bulk handling, transport and warehouse storage ofpackaged products. See also primary packaging and secondary packaging.Thermoforming – the process of shaping a plastic sheet of packaging film under heat and pressure.Three-side-seal pouch – a pouch that is formed by folding the web material into a U-shape and thensealing the three open sides. The pouch may be made with a gusseted bottom. TiroBox – a GEA pack format that uses a pre-folded cardboard packaging that is lined with film in thepackaging machine. Foods packaged in this way can be reconstituted in a microwave oven, making itan ideal technique for ready meals. TiroLabel – the GEA labeling solution for thermoformers or vertical baggers.TiroPrint – the GEA printing solution for integrating into a thermoformer.Top film (infeed) – the film that is fed from a roll to form the top or lid of the pack at the sealingstation. See also bottom film.Transverse direction – the direction perpendicular (90 degrees) to the direction a film travelsthrough a machine during processing. Trays – pre-formed trays for use with a tray sealer (such as the GEA TwinStar) that can be combinedwith easy-opening features and reclosable techniques.TwinTube – a unique GEA SmartPacker configuration that produces 2 bags side-by-side, andtherefore effectively doubles the maximum achievable speed.

Ultrasonic seal technology – a sealing technique that uses high-frequency vibration of a sonotrodeto bond two layers of film together. It is very effective and forms a hermetic seal even if moisture orother debris remains in the seal area after the bag is filled.

Vacuum pack – a pack format for horizontal thermoformers (such as the GEA PowerPak) that offers along shelf life and is economical with packaging material. Air is removed from the pack prior tosealing.

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W - Z

Web – completed packaging material, usually only used to describe the packaging material while stillon their roll and before first use.

Zig-zag opening – an easy-opening feature for tearing open trays.Zipper pouch – a flexible plastic pouch with a molded-in-place sealing device featuring a projectingrib that is inserted into a mating channel to close the pouch. A zipper seal can be repeatedly openedand closed.

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Notes

57

Notes

58

Contents

GEA FOOD SOLUTIONS 3



GEA SOLUTIONS FOR: BAGS, VACUUM PACKS, FORMED AND PREFORMED TRAYS


HOW BAGS ARE MADE






DIFFERENT PACKS 26

OPTIONS FOR TRAYS (IN-LINE) 34

HOW TRAYS ARE SEALED 39

DIFFERENT PREFORMED TRAY APPLICATIONS 42

43


PACKAGING FILMS 45



GEA SMARTPACKER 48

GEA POWERPAK 52

GEA TWINSTAR 56

TECHNICAL DATA POWERPAK RANGE 58


CUTTING FEATURES

All rights reserved ©No part of this document may be reproduced or transmitted in any form or by any means,

without prior written permission of GEA Food Solutions.

ImprintGEA Food Solutions Beekakker 11 5761 EN Bakel The Netherlands

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11

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15

Content

OUR COMPANY 3



GEA SOLUTIONS FOR BAGS, TRAYS AND VACUUM PACKS 10

GEA VERTICAL PACKAGING SOLUTIONS 11

HOW BAGS ARE MADE 12

A VARIETY OF WELDING/HEAT SEALING SYSTEMS 15





DIFFERENT PACKS 26

OPTIONS FOR TRAYS (in-line) 34


PACKAGING FILMS 39



GEA SMARTPACKER 42

GEA POWERPAK 46


ADDITIONAL EQUIPMENT 48

GEA0515614881_B07.00.04EN_102015 GEA Packaging Guide Cover.indd 2-59 20/10/15 11:34

GEA

Packaging Guide

Επίσημος Αντιπρόσωπος:Επίσημος Αντιπρόσωπος:

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